zpp 416 operator manual...charging. • disconnect the battery negative (earth) lead first and...

Revision-0 June 21, 2017

ZPP 416

OPERATOR MANUAL

Stationary & Constant-Speed Mobile Industrial Engines

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Service Parts To ensure that your engine continues to run reliably and efficiently for as long as possible, use only genuine Zenith Pow-er Products (ZPP) parts. For genuine ZPP service parts for your engine, or for technical assistance in servicing your engine, call:

1-276-525-4760 Hours: Monday-Thursday: 8:00 – 5:00 Eastern Time Friday: 8:00 – 12:00 Eastern Time Maintenance Providers Maintenance and repair services may be performed by you or any qualified engine service provider that you choose. However, your engine warranty does not cover damage or failure caused by improper maintenance or repairs. Disclaimer All information and specifications in this manual are based on the latest data available at the time of the publication. Zenith Power Products reserves the right to make changes or improvements at any time without notice. For additional information see:

www.ZenithPowerProducts.com


Foreword

This booklet has been prepared to provide the necessary information for the operation, inspection and maintenance of the ZPP Engine.

We urge you to follow the recommendations contained in this booklet so that the ZPP Engine will remain free of trouble throughout its working life. Please familiarize yourself with the booklet and refer to it when necessary.

If you encounter any problems with your ZPP Engine contact the authorized ZPP dealer in your area.

Your 416 engine is configured to operate on one of the following types of fuels:

• Gasoline (87 octane)

• LPG (HD-5 or better)

• Natural Gas (Pipeline quality)

Contents

Safety Symbols & Precautions ...............................4

Operation ............................................................... ...5

Fuels………………………………………………..…….7

Other Handling and Operations ........................... 10

Maintenance ........................................................... 12

Drive Belt Inspection .............................................. 14

Changing Oil & Filter .............................................. 15

Selection of Engine Oil ..........................................17

Engine Coolant ........................................................ 18

Compression Test ..................................................18

Valve Adjustment ................................................... 20

General Information ................................................ 21

Maintenance Schedule ..........................................22

Diagnostics .............................................................24

Warranty ..................................................................32

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SAFETY SYMBOLS This section identifies the ISO 8999 symbols that may be used in this manual.

Battery

Read the handbook

Warning

Engine coolant fill level

Electrical hazards

No smoking or flame

Engine oil fill level

Engine coolant temperature

Engine coolant pressure

Hot surface warning

Engine oil pressure


General Precautions • Ensure the engine is securely mounted.

• Keep the engine and surrounding area clean.

• Keep all safety guards in position. • Keep the body and clothing clear of all moving or hot

parts.

• Thoroughly clean any lubrication oil or fuel from the skin as soon as practicable after contact.

• Rectify all fuel, water and oil leaks as soon as practicable and clean any spillages when they occur.

Lifting Precautions The following points must be considered before attempting to lift the engine.

• Ensure the lifting equipment to be used has the correct capacity to lift the engine.

• Single lifting equipment must only be used when a single lifting eye if fitted.

• When two engine lifting eyes are fitted suitable lifting equipment designed to give two vertical lifts from directly above the engine lifting eyes must be used.

• Check that the engine lifting eyes are not damaged and that they are secure.

• To prevent damage to the cylinder head cover, en-sure that there is clearance between the lifting equipment hooks and the cover.

OPERATION The life and performance of an engine are greatly influenced by how it is handled and serviced dur-ing the initial period of operation. Operate the engine by observing the following precautions during the first 100 hours of operation.

CAUTIONS IN OPERATION 1. After starting, warm the engine until the 2. coolant temperature rises above

50°C (122°F).

2. Never attempt to race the engine under non-loaded conditions.

3. Avoid overloading the engine.

4. Use only gasoline with an octane rating of 87 min.

NOTE: THIS ENGINE IS NOT DESIGNED FOR USE WITH E-85 ETHANOL BASED FUEL. DAMAGE TO THE ENGINE CAN OCCUR WHICH MAY VOID YOUR WARRANTY.

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Alternator Precautions The following points must be strictly observed when an alternator is fitted, otherwise serious dam-age may result.

• Never remove any electrical cables while the battery is connected in the circuit.

• Only disconnect the battery with the engine stopped and all switches in the OFF position.

• Always ensure that cables are fitted to their correct terminals.

• A short circuit or reversal of polarity will ruin diodes and transistors.

• Never connect a battery into the system with-out checking that the voltage and polarity are correct.

• Never ‘flash’ any connection to check the cur-rent flow.

• Never experiment with any adjustments or re-pairs to the system.

• The battery and alternator must be disconnect-ed before commencing any electric welding when a pole strap is directly or indirectly con-nected to the engine.

Starter and Battery Precautions • Do not smoke near the batteries.

• Keep sparks and flames away from the batteries.

• Batteries contain sulfuric acid – if the acid has been splashed on the skin, eyes or clothes, flush it away with copious amounts of fresh water and seek medical aid.

• Keep the battery well ventilated during charging.

• Disconnect the battery negative (earth) lead first and reconnect last.

• Switch off any battery charger before disconnecting the charger leads.

• Never ‘flash’ connections to check current flow.

• Never experiment with adjustments or repairs to the system.

• A damaged or unserviceable battery must nev-er be used.


FUELS Gasoline, natural gas and LPG are combustible gases, and can be explosive if leaked and contained in a confined area. Keep cigarettes and all other flame sources away from these areas. If you can hear a fuel leak, shut off the fuel supply at the source immediately and fix the leak or have it serviced. Check the entire fuel supply line from the cylinder/tank to the engine for leaks with a soapy water bubble mixture anytime a cylinder/tank is changed or the fuel supply line is worked on. Fuel leaks should also be checked as part of the regular engine maintenance. Depending on your engine and fuel system configuration, your engine is designed to run on natural gas and/or vapor LPG. The fuel requirements for each are dis-cussed below. See the "SPECIFICATIONS" section for the required fuel supply pressures for each fuel.

Natural Gas Your engine is certified to run on "pipeline-quality natural gas". EPA defines pipeline-quality natural gas as being supplied by a pipeline and being composed of at least 70% methane by volume or having a heating value of 950-1100 BTUs per cubic foot. If your natural gas supply does not meet these specifications, your engine is con-sidered to be being operated as a non-certified engine. See "U.S. EPA Legal Requirements" at the front of this manual.

LPG In order to maintain emissions compliance and the en-gine warranty, use commercial-grade HD-5 or better LPG. Liquid LPG is drawn off of the bottom side of a LPG tank or cylinder and is a liquid until it has passed through the regulator/vaporizer, at which point it is vaporized to a gas. If you connect vapor LPG to a liquid LPG fuel sys-tem, you may starve the engine for fuel, causing it to produce low power and excessive emissions. Vapor LPG is drawn off of the top side of a LPG tank or cylinder and is a gas from the tank/cylinder through to the engine intake. If you connect liquid LPG to a vapor LPG fuel system the fuel will not vaporize properly, caus-ing the engine to run rich, produce low power and exces-sive emissions.

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SAFETY PRECAUTIONS

Starting an engine incorrectly may cause injury to the operator and/or cause damage to the en-gine. Engine operators must be instructed in the correct procedures before attempting to start any engine.

Before Starting

• Inspect the engine, intake, exhaust, cooling system, and drivetrain to verify that the engine is fully assem-

bled and not in the process of being serviced.

• Ensure the engine is free to turn without obstruction.

• Check that all safety guards are in their correct posi-tion and secure.

• Check that the coolant level in the radiator overflow bottle is between "Add" and "Full".

• Check that the oil level on the dipstick is between "Add" and "Full".

• Check that the fuel supply is connected, shut-off valves are open, and there are no leaks.

• If a LPG fuel system is being used, verify that there is fuel in the cylinder/tank.

• If a natural gas fuel system is being used, verify that the correct fuel supply pressure is being supplied to

the engine.

WARNING


STARTING, RUNNING, & STOPPING THE ENGINE

Observe the safety precautions listed in "SAFETY PRECAUTIONS - STARTING" before starting the engine. Starting the engine

• Turn the key switch to the ON position and verify that the MIL is illuminated. If not deter-mine why the lamp is not working.

• Turn the key switch to the START position and

hold until the engine has started.

• Release the key promptly after the engine

starts to avoid grinding the starter.

• Do not crank the engine for more than 15

seconds at a time.

• Allow at least 30 seconds between cranking

attempts. If the engine does not start after 3 starting attempts, review the "Before Starting" checklist.

Running the engine

• Do not race or fully load the engine during the first 3 minutes of operation.

• Verify that the "CHECK ENGINE" light is off while the engine is running. If it is on, refer to the DIAGNOSTICS section.

• Verify that there are no fuel, coolant, or oil leaks while the engine is running. If there are leaks, stop the en-gine and fix them or have the engine serviced.

• Listen to the engine. If you hear an abnormal noise while the engine is running, turn it off and correct the problem or have the engine serviced.

• No adjustments are necessary to the fuel or ignition systems.

Stopping the engine

• If the engine has been running under load and is hot, run the engine at no load for 3 minutes to allow the engine to cool before stopping the engine.

• Stop the engine by turning the key switch to the OFF position. The engine may run-on for 1-5 seconds while the fuel is depleted from the carburetor and the air/fuel mixture is depleted from the intake manifold.

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CAUTIONS DURING OPERATION During engine operation, all warning light(s) should remain OFF. If the Low Oil Pressure or High Coolant Temp lights turn ON, immediately stop operation. Service the engine after it has cooled to a safe temperature. If the yellow or amber "CHECK ENGINE" light turns on, you may continue operating the engine for a short period of time. Have the engine serviced as soon as possible. If any other abnormalities such as unusual noise, vibration or shocks are observed, stop the opera-tion and make the necessary inspection and repair. AT COMPLETION OF THE DAYS OPERATION 1. Make sure that there are no oil leaks, water

leaks, or any other defects.

2. Clean the exterior of the engine so that any oil leak, water leak, fuel leak or other defect may be easily detected.

3. Repair any faulty parts detected during

OTHER HANDLING AND OPERATIONS IN COLD WEATHER

• Oil Use engine oil suitable for ambient temperature (refer to "SELECTION OF ENGINE OIL").

• Coolant When coolant might freeze under low ambient temperature, precautions must be taken. It is recommended to utilize a mixture of 50-70% antifreeze, balance water. Refer to your antifreeze specifications for the exact mixture needed.

• Battery The battery should never be left in a discharged state. When battery performance becomes questionable, check the specific gravity of the electrolyte, terminals of the battery for corrosion and the alternator belt for looseness.


IN HOT WEATHER

• Oil Engine oil should be changed to summer grade oil (refer to "SELECTION OF ENGINE OIL").

• Coolant Because the engine is more likely to overheat in hot weather, the cooling system should be inspected and maintained. Overheating sometimes comes from improper coolant levels, incorrect antifreeze to water ratios, defective hoses, connections, loosened/weak radiator cap, or defective fan belt. So check the cooling system carefully to maintain the best cooling effect. Again, it is recommended to utilize a mixture of 50-70% antifreeze, balance water. Refer to your antifreeze specifications for the exact mixture needed.

• Battery Since the battery electrolyte evaporates in hot

WHEN USING THE ENGINE ONLY DURING A PARTICULAR PERIOD OF THE YEAR When the engine is to be used only in a particular period of the year, such as summer or winter, the service life of the engine will be determined by how it is maintained during the out-of-use period. Follow the procedures below when preparing the engine. During in-use period Follow the normal handling procedures during this period. During out-of-use period During the out-of-use period, perform the following maintenance procedures for the engine. 1. Perform loaded operation once a month.

• Run the engine and perform basic engine checks.

• Apply a load in excess of 50% of the rated load to the engine, and operate it for more than 10 minutes. Make sure that no abnormal noise or vi-bration is produced.

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2. Perform the following inspection and

adjustment before placing the engine in use period.

• Drain sediment from the fuel system (fuel filter and fuel tank).

• Change engine oil and oil filter element.

• Check and adjust fan belt tension.

• Check battery electrolyte level and specific gravity.

• Change air cleaner element.

• Check antifreeze protection and level.

MAINTENANCE

Daily Care In order to prevent trouble in daily operation, it is necessary that the operator be constantly aware of the condition of the engine. To assure this, the operator must personally inspect the engine before starting the day’s activities. If you note any defects, notify your supervisor or authorized ZPP dealer.

CHECKING THE ENGINE FOR LEAKAGE 1. Ensure that the engine, radiator and hoses are not

cracked and show no signs of leaking.

2. Check each portion of the engine, to ensure that there is no sign of an oil leak.

3. Check the fuel system to make sure that there is no sign of fuel leaking from the fuel system.


CHECK THE ENGINE OPERATION DURING BOTH IDLING AND ACCELERATION Make sure that the engine runs normally at idling speed, and that engine rpm increases smoothly as it is accelerated.

OTHER Correct all of the faults and problems that were observed during the previous day’s operation. If any faults are discovered during the daily inspection, contact an authorized ZPP dealer for additional inspection, adjustment or repair. Always maintain the engine in its top condition.

ON-VEHICLE INSPECTION

CAUTION

• Check that the battery cables are connected to the correct terminals.

• Disconnect the battery cables when the battery is given a quick charge.

• Never disconnect the battery while the

CHECK BATTERY VOLTAGE

1. If 20 minutes have not passed since the engine was stopped, turn the ignition switch ON and turn on all electrical loads (headlamp, blower motor, auxiliary mo-tors, etc.) for 60 seconds to remove the surface charge.

2. Turn the ignition switch OFF and turn off the electrical systems.

3. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery.

Standard battery voltage: 12.5 ~ 12.9 V at 20

oC (68

oF)

Proper charging voltage: 14.4 ~ 14.8 V

If the battery voltage is less than specification, charge the battery.

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CHECK THE BATTERY TERMINALS AND FUSES 1. Check that the battery terminals are not loose

or corroded. 2. Check the fuses for continuity.

INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt.

NOTE: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks miss-ing

Measure the drive belt tension and adjust it. Apply a force of 98N (10kg, 22lb), and measure the deflection between the alternator and crankshaft pulley.

DEFLECTION

New belt: 0.13 in. to 0.15 in.

Used belt: 0.17 in. to 0.19 in.

If the belt tension is not as specified, adjust it. NOTE:

• “New belt” refers to a belt which has been used less than 5 minutes on a running engine. “Used belt” refers to a belt which has been used on a running en-gine for 5 minutes or more.

• After installing a belt, check that it fits properly in the ribbed grooves.

• Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

• After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.


VISUALLY CHECK ALTERNATOR WIRING AND LISTEN FOR ABNORMAL NOISES Check that the wiring is in good condition. Check that there is no abnormal noise from the alternator while the engine is running. CHECK DISCHARGE WARNING LIGHT CIRCUIT Warm up the engine, and then turn it off. Turn off all accessories. Turn the ignition switch “ON”. Check that the discharge warning light is lit. Start the engine. Check that the light is lit. If the light does not go off as specified, troubleshoot the discharge light circuit.

CHANGING OIL AND FILTER

CAUTION

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness and irritation. In addition, used engine oil contains potentially harmful contaminants which may

Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and gloves. Wash your skin thor-oughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites.

DRAIN THE ENGINE OIL

1. Remove the oil filler cap.

2. Remove the oil drain plug and drain the oil into a

container.

REPLACE THE OIL FILTER

1. Remove the oil filter.

2. Check and clean the oil filter installation surface.

3. Check that the part number of the new oil filter is

correct.

4. Apply clean engine oil to the gasket of the new oil filter. Screw new filter on finger tight.

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REFILL WITH ENGINE OIL

1. Clean and install the oil drain plug with a new

gasket.

2. Fill with fresh engine oil.

3. Install the oil filler cap.

4. Start engine and check for oil leaks.

5. Recheck the engine oil level.

Oil quantity (Oil pan) 3.0 L (3.17 US qt.)

Oil quantity (Oil filter) 0.3 L (0.32 US qt.)

Oil quantity (Total) 3.3 L (3.49 US qt.)

INSPECTION 1. Check the engine oil quality. Check for oil deterioration,

entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil.

2. Check the engine oil level. After warming up the engine for five minutes, stop the engine and check the oil level. The level should be between the “L” and “F” marks on the dipstick. If low, check for oil leakage and add oil up to the “F” mark on the dipstick.

NOTE:

Do not fill with engine oil above the “F” mark.

CAUTION

Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result.


SELECTION OF ENGINE OIL API SERVICE GRADE CERTIFIED

Use engine oil that is API Service Grade Certified.

Recommended API classification:

SG OR ABOVE

SAE VISCOSITY An SAE viscosity grade is used to specify the

viscosity of engine oil. SAE 10W-30 specifies

multiple viscosity engine oil. When choosing

engine oil, consider the range of temperatures

the vehicle will be operated in before the next

oil change. Select engine oil that is best suited

to your area’s particular ambient temperature

range and variation.

ENERGY CONSERVING OIL An Energy Conserving type oil is recommended

for gasoline engines. The designation of

ENERGY CONSERVING is located on the label

of an engine oil container.

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ENGINE COOLANT WARNING: To avoid the danger of being scalded, never attempt to change the coolant when the engine is hot. When using antifreeze coolant, mix the antifreeze coolant with water, observing instructions attached to antifreeze container. Use only antifreeze approved for aluminum components. Clean outside of radiator with dry compressed air. Checking cooling system hoses and connections: Check hoses and fittings for loose connections or for any sign of oil deterioration or soft spots in the hoses. Retighten or replace if necessary.

CHECKING ENGINE COMPRESSION PRESSURE

Note: Engine compression measurement should be made as quickly as possible.

The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnostic purposes.


CHECKING ENGINE COMPRESSION PRESSURE

(continued) 1. Clean the spark plug recesses with

compressed air.

2. Remove the spark plugs.

3. Disable the fuel system.

4. Disconnect the ignition coil.

5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.

Compression pressure:

218 psi (15.0 kg/cm2, 1500 kPa) at 370 rpm

Minimum pressure:

203 psi (14.0 kg/cm2, 1400 kPa)

Difference between each cylinder:

14 psi (1.0 kg/cm2, 98 kPa) or less

If cylinder compression in one or more cylinders is low, pour a small quantity of engine oil into cylinders through the spark plug holes and retest compression.

• If adding oil helps the compression pressure, the piston rings are probably worn or damaged.

• If pressure stays low, valve may be sticking or sealing improperly.

• If cylinder compression in any two adjacent cylinders is low, and if adding oil does not help the compression, there is leakage past the gasket surface. Oil and water in combustion chambers can result from this problem.

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REPLACING FUEL FILTER Your gasoline ZPP engine is provided with a gaso-line fuel filter. The filter is located in the suction line just before the fuel pump. The fuel filter should be checked periodically, and replaced when dirty and/or plugged.

CHECKING FUEL LINES (HOSES, PIPING, CONNECTIONS) NOTE: Gasoline fuel hoses must meet the EPA and CARB guidelines for “low permeability” as part of the CFR 1048 emissions requirements. Check fuel lines for proper attachment, leaks, cracks, damage, loose connections, chaffing and deterioration. If necessary, replace any damaged or defective parts.

VALVE ADJUSTMENT The ZPP 416 engine does not require valve adjustment because the 416 is equipped with hydraulic valve lash adjusters.


GENERAL INFORMATION

ENGINE FUELS Gasoline (87 octane) LPG (HD-10 or better) Natural Gas (Pipeline ) TYPE IN-LINE DOHC # CYL. 4 BORE 76.5 mm STROKE 87.0 mm TOTAL DISPLACEMENT 1599 cc COMPRESSION RATIO 10.0 : 1 FIRING ORDER 1-3-4-2 OIL FILTER PART NUMBER H26300 35503 OIL CAPACITY 3.3 L (WITH FILTER) SPARK PLUG - PLATINUM NGK BKR5ES-11 SPARK PLUG GAP 1.00 - 1.10 MM 0.39 - 0.43 IN

ALTERNATOR TYPE BATTERY VOLTAGE SENSING RATED VOLTAGE 13.5 V, 90 AMPS VOLTAGE REGULATOR INTERNAL

REGULATOR VOLTAGE 14.55 ± 0.2 V

STARTER RATED VOLTAGE 12 VOLTS. 0.9 Kw # of PINION TEETH 8 NO-LOAD SPECS. 11.5 VOLTS 60 AMPS MAX. 5500 rpm, MIN.

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Periodic maintenance should be performed after specified Months 1 2 3 4 5 6intervals have elapsed in months or hours, whichever comes first Hours 250 500 750 1000 1250 1500

I I I I I I

Engine timing belt

T

(A) C C

(A) R R R R R R

(A) R R R R R R

R

(A) I I I I I I

I

(A) I

I

I I

ADDITIONAL MAINTENANCE

1. Fuel line supply and connectors portion for gas leakage (B) I I I I I I

2. Fuel line supply and connectors for damage (B) I I I I I I

3. LPG filter I/R I/R

4. Vaporizer/Regulator Plug (oil contamination) I/D

5. LPG lock-off I

Notes:

B) At time of LPG cylinder replacement, inspect tank connections for leakage with soapy water.

Abbreviations: I = InspectionI = InspectionR= ReplaceA= AdjustC= CleanD= DrainT= Retighten

PCV hoses

Check fuel supply & return lines for leaks

ZPP-416 LSI ENGINE AND EFI

This table lists the periodic maintenance required to ensure quality performance and good

Spark Plugs

Spark Plug Wires

PCV valve

A) Under heavy duty operating condition, more frequent maintenance may be necessary

Drive belt tension

Intake and Exhaust manifold nuts

Radiator outside

Engine oil

Oil Filter

Engine coolant

Fuel Filter gasoline

Air cleaner element


7 8 9 10 11 12 13 14 15 16 17 18 19 201750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500 4750 5000

I I I I I I I I I I I I I I

R

T T

C C C C

R R R R R R R R R R R R R R

R R R R R R R R R R R R R R

R R

R R R R

I I I I I I/R I I I I I I I I

R R

I I R

I I I I

I I I I

I I I I

REQUIREMENTS FOR LPG FUEL SYSTEM



R I/R I/R R

I/D I/D I/D

I/D I I

MAINTENANCE SCHEDULE

mechanical condition of the engine, fuel system, and catalytic converter in your application.

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DIAGNOSTICS How to manage and retrieve fault codes The Engine Control Module (ECM) uses fault codes to identify and report control system faults. The ECM has three ways of reporting fault codes to the service technician. Each method uses a unique fault code format.

Each fault has a unique set of codes and an asso-ciated diagnostic procedure. Each fault and its as-sociated codes are listed in the “Fault Code List” following this section.

# Device Code Format

1 Malfunction Indicator Lamp (MIL)

Flash codes

2 J1939 CAN (Controller Area Network) Link

SPN & FMI codes

3 PC Service Tool

DTC codes

If the MIL is on while the engine is running, service the engine as soon as possible.

Extended engine operation with a fault condition may lead to engine and/or catalyst damage.

The ECM will automatically clear a fault code from its memory if the engine completes 20 consecutive start-run-stop cycles without the fault recurring. Malfunction Indicator Lamp (MIL) The MIL, or Check Engine lamp, is a light on the engine control panel. The MIL is usually yellow, amber, or orange. As a bulb check, the ECM turns on the MIL when the igni-tion key is on and the engine is not running. If the MIL is off during this condition, check for a burned-out bulb or wiring problem. If the engine is running and the MIL is off, there are no cur-rent or recent faults to report. If the MIL is on while the engine is running, the ECM has a fault to report. The MIL will stay on for 3 start-stop cycles after a fault is detected. The MIL will turn off on the 4th cy-cle if the fault has not recurred during the previous 3 cycles.


DIAGNOSTICS - CONTINUED To retrieve flash codes from the ECM:

1. Install the 201985 shorting cap on the COMM

connector or ground the Brown/White pin of the COM/DIAGNOSTIC connector.

2. Turn the ignition key on without starting the

engine.

3. The ECM will flash the leader code (111), then

the fault code(s), then trailer code. Each code is repeated 3 times.

J1939 CAN Link The ECM also reports faults over the J1939 CAN link. If the engine is equipped with a CAN monitor or the technician has access to a handheld CAN reader, the technician can retrieve the fault codes from the CAN link. The J1939 CAN standard uniquely defines each fault using a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI).

PC Service Tool The “GCP Display” PC service tool reports a unique Diag-nostic Trouble Code (DTC) and a text fault message for each fault. The PC service tool also displays the values read from each sensor both in terms of the signal voltage/frequency and the engineering units (kPa, degrees C, etc.) which is very helpful for diagnosing signal faults. The PC service tool also allows the service technician to clear the fault codes.

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FAULT CODE LIST

DTC Fault

CAN

SPN

CAN

FMI

MIL Flash

Code

Leader/Trailer Code 111

0016 CRANK or CAM could not synchronize during start 636 8 216

0107 MAP Signal open or shorted to ground 106 4 127

0108 MAP signal shorted high 106 16 128

0112 IAT signal Low/Shorted to GND 105 4 112

0113 IAT signal High/Open 105 3 113

0116 ECT higher than warning threshold 110 15 116

0117 ECT Sensor Low/Shorted Input 110 4 117

0118 ECT Sensor High/Open Input 110 3 118

0121 TPS1 voltage lower than TPS2 voltage 51 1 121

0122 Throttle Position Signal 1 low voltage 51 4 122

0123 Throttle Position Signal 1 high voltage 51 3 123

0151 LPG Closed-loop: A/F is too lean 520206 0 151

0152 LPG Closed-loop: A/F is too rich 520206 1 152

0171 Gasoline A/F is too lean (adaptive learn) 520200 0 171

0172 Gasoline A/F is too rich (adaptive learn) 520200 1 172


DTC Fault

CAN

SPN

CAN

FMI

MIL Flash

Code

0182 Gasoline Fuel Temp Low Voltage 174 4 182

0183 Gasoline Fuel Temp High Voltage 174 3 183

0187 LPG Fuel Temp Low Voltage 520240 4 187

0188 LPG Fuel Temp High Voltage 520240 3 188

0217 ECT higher than engine shutdown threshold 110 0 217

0219 Engine Overspeed Condition 515 15 219

0221 TPS1 voltage higher than TPS2 voltage 51 0 221

0222 Throttle Position Signal 2 low voltage 520251 4 222

0223 Throttle Position Signal 2 high voltage 520251 3 223

0291 Gasoline Fuel Pressure low voltage 94 4 291

0292 Gasoline Fuel Pressure high voltage 94 3 292

0336 CRANK signal noise 636 2 336

0337 No CRANK signal 636 4 337

0341 CAM signal noise 723 2 341

0342 No CAM signal 723 4 342

0359 Fuel (LPG or NG) run-out longer than expected 0 31 359

0421 Catalyst inactive on gasoline 520211 10 421

0524 Engine Oil Pressure Too Low 100 1 524

0562 Battery Voltage Low 168 17 562

0563 Battery Voltage High 168 15 563

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FAULT CODE LIST - CONTINUED

DTC Fault

CAN

SPN

CAN

FMI

MIL Flash

Code

0601 Microprocessor failure - FLASH 628 13 621

0604 Microprocessor failure - RAM 630 12 624

0606 Microprocessor failure - COP 629 31 626

0615 Starter relay coil open 1321 5 615

0616 Starter relay control short to GND 1321 4 616

0617 Starter relay coil short to 12V 1321 3 617

0637 Pin 85 (AUX_PWM4) open/short to GND 700 5 637

0638 Pin 85 (AUX_PWM4) short to 12V 700 6 638

0642 5V Reference #1 voltage low 1079 4 642

0643 5V reference #1 voltage high 1079 3 643

0650 Malfunction Indicator Lamp open 1213 5 651

0652 5V Reference #2 voltage low 1080 4 652

0653 5V Reference #2 voltage high 1080 3 653

0685 Power relay coil open 1485 5 685

0686 Power relay short to GND 1485 4 686

0687 Power relay short to 12V 1485 3 687

1153 NG Closed-loop: A/F is too lean 520207 0 153

1154 NG Closed-loop: A/F is too rich 520207 1 154


DTC Fault

CAN

SPN

CAN

FMI

MIL Flash

Code

0155 Gasoline Closed-Loop: A/F is too lean 520204 0 155

0156 Gasoline Closed-loop: A/F is too rich 520204 1 156

1161 LPG Adaptive-learn: A/F is too lean 520202 0 161

1162 LPG Adaptive-learn: A/F is too rich 520202 1 162

1163 NG Adaptive-learn: A/F is too lean 520203 0 163

1164 NG Adaptive-learn: A/F is too rich 520203 1 164

0165 Catalyst inactive on LPG 520213 10 165

0166 Catalyst inactive on Nat Gas 520214 10 166

1171 EPR delivery pressure higher than expected 520260 0 371

1172 EPR delivery pressure lower than expected 520260 1 372

1173 EPR-ECU communications lost 520260 31 173

1174 EPR voltage supply high 520260 3 174

1175 EPR voltage supply low 520260 4 175

1176 EPR internal actuator fault detected 520260 12 176

1177 EPR internal circuitry fault detected 520260 12 177

1178 EPR internal communications fault detected 520260 12 178

1515 AUX 5V ANALOG INPUT 4 open or high 520215 3 515

1516 AUX 5V ANALOG INPUT 4 low 520215 4 516

1517 AUX 5V ANALOG INPUT 3 open or high 520218 3 517


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FAULT CODE LIST - CONTINUED

DTC Fault

CAN

SPN

CAN

FMI

MIL Flash

Code

1541 AUX 5V ANALOG INPUT 1 high 520219 3 541

1542 AUX 5V ANALOG INPUT 1 low or open 520219 4 542

1543 AUX 5V ANALOG INPUT 2 high or open 520220 3 543


1551 AUX DIGITAL INPUT 1 high 520222 4 551

1552 AUX DIGITAL INPUT 1 low 520222 3 552





1563 AUX 5V ANALOG INPUT 5 open or high TBD TBD 563

1564 AUX 5V ANALOG INPUT 5 low TBD TBD 564


DTC Fault

CAN

SPN

CAN

FMI

MIL Flash

Code

1612 Watchdog processor blocked outputs (RTI 1) 629 31 712

1613 Microprocessor failure - RTI 2 629 31 713

1614 Microprocessor failure - RTI 3 629 31 714

1615 Microprocessor failure - A/D 629 31 715

1616 Microprocessor failure - Interrupt 629 31 716

1644 MIL control short to GND 1213 4 644

1645 MIL control short to 12V 1213 3 645

2111 Unable to reach Lower TPS 51 7 211

2112 Unable to reach higher TPS 51 7 212

2115 APP1 higher than IVS 91 0 315

2121 APS/IVS Conflict 91 18 321

2122 APP1 signal low voltage 91 3 322

2123 APP1 signal high voltage 91 4 323

2130 IVS stuck at idle, APP 1/2 mismatch 558 5 332

2131 IVS stuck at off-idle, APP 1/2 mismatch 558 6 331

2139 APP1 lower than IVS Limit 91 1 339

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Engine Warranty - Term & Provisions Warranty Provisions Zenith Power Products, LLC warrants that this engine was designed, built, and equipped so that it fully complies with the applicable emissions standards of U.S. EPA 40 1048 at the time of sale to you, the end customer, and that the engine is free of defects in materials and workmanship that may keep it from meeting the emissions standards.

Base Warranty Period

Emissions-Related Warranty Period Your engine's emissions-related warranty period is 2500 operating hours or 3 years, whichever comes first. The engine's operating hours are determined based on the Engine Control Module’s (ECM’s) hour meter. The emissions warranty period begins on the date the engine or equipment is placed into service. Owner Obligations This warranty is valid only if you operate and maintain your engine as specified in this Owners Manual. In particular, you must maintain your engine as specified in the Maintenance Schedule. How to contact us regarding a warranty claim Call 276-525-4760 during normal business hours (8-5 eastern time Monday-Friday) or E-Mail [email protected].

Rating Months Hours

Stationary and Constant Speed Mobile 12 2500

Variable Speed Mobile 24 2000

Emergency Standby 24 400


Engine Emissions Warranty - Components Covered

• Air-Valve Carburetor (Mixer)

• Catalytic converter

• CAM sensor

• CRANK sensor

• Engine Control Module (ECM)

• Engine Coolant Temperature (ECT) sensor

• Electronic throttle

• Engine wiring harness

• Exhaust manifold

• Gasoline Fuel Injectors

• Fuel pressure regulator

• Ignition coil pack

• Intake manifold

• Manifold Absolute Pressure/Intake Air Temperature (TMAP) sensor

• Positive Crankcase Ventilation (PCV) valve

• Pre-catalyst oxygen sensor

• Post-catalyst oxygen sensor

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NOTES:

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ZENITH POWER PRODUCTS LLC

26502 Newbanks Road Abingdon, VA. 24210

276-525-4760

www.ZenithPowerProducts.com

zpp 416 operator manual...charging. • disconnect the battery negative (earth) lead first and...

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